Production of higher olefins

ABSTRACT

A method of making a higher olefin product from a C 4   +  fraction separated from the hydrocarbon product produced by an oxygenate to olefin reaction unit. The C 4   +  fraction primarily contains butenes which may be directed to a higher olefin reaction unit without removing isobutenes, butanes, and/or butadiene. The C 4   +  fraction is particularly well suited for the production of higher olefins because of its high olefin content, low branching number, and low contaminent levels. The invention is also directed to an olefin product composition that is produced by contacting the C 4   +  fraction with an oligomerization catalyst. The olefin composition is characterized by a relatively high octene content, and octene with a branching number less than 1.4.

This application claims priority to U.S. Provisional Patent ApplicationNo. 60/265,700, filed Feb. 1, 2001.

FIELD OF THE INVENTION

This invention relates to a system of making olefin derivatives, namelyhigher olefin, from olefin produced from an oxygenate. The higher olefinmay then be used to produce a variety of olefin derivative productsincluding alcohols, aldehydes, acids and esters.

BACKGROUND OF THE INVENTION

Olefins such as butenes and pentenes are useful in preparing a widevariety of derivative end products. Examples of such end productsinclude alcohols, aldehydes acids and esters. The butenes and pentenescan also be oligomerized to form higher olefins having eight or morecarbons. The higher olefins may be linear or they may have one or morealkyl branches. The higher olefins can then be converted to alcohols,aldehydes, acids and esters.

Butenes used in preparing olefin derivative products are typically madeby cracking hydrocarbon feedstocks, i.e., producing low molecular weighthydrocarbons from high molecular weight hydrocarbons. Cracking ofhydrocarbon feedstocks can be accomplished catalytically ornon-catalytically. Non-catalytic cracking processes are described, forexample, in Hallee et al., U.S. Pat. No. 3,407,789; Woebcke, U.S. Pat.No. 3,820,955, DiNicolantonio, U.S. Pat. No. 4,499,055 and Gartside etal., U.S. Pat. No. 4,814,067. Catalytic cracking processes aredescribed, for example, in Cormier, Jr. et al., U.S. Pat. No. 4,828,679;Rabo et al., U.S. Pat. No. 3,647,682; Rosinski et al., U.S. Pat. No.3,758,403; Gartside et al., U.S. Pat. No. 4,814,067; Li et al., U.S.Pat. No. 4,980,053; and Yongqing et al., U.S. Pat. No. 5,326,465.

One problem with using a hydrocarbon cracking unit to produce olefins isthat the olefins contain a significant degree of alkyl branched olefin.For example, in a butenes stream, isobutene must first be removed beforethe butenes are directed to an oligomerization unit. The presence ofisobutene in the butenes feed will result in branched higher olefin,which leads to branched alcohols. Branched alcohols have relativelylittle commercial value because they result in inferior plasticizers.

Another problem with olefin produced by a hydrocarbon cracking unit isthat the olefin contains significant quantities of sulfur and nitrogencompounds. These compounds deactivate the acidic catalysts used inolefin derivative processes, such as olefin oligomerization. Forexample, Bodart, U.S. Pat. No. 5,432,243, and Debras et al., U.S. Pat.No. 4,861,939, disclose that arsine and carbonyl sulfide (COS) can beproblematic in the olefin derivative process unless the contaminants areremoved by additional purification equipment. U.S. Pat. No. 5,146,042 toGurak et al. suggests that sulfur contaminants in C₂ to C₄ olefin canlead to undesirable side reactions in higher olefin and olefinderivative processes. Purification of such olefin requires that thecontaminants be extracted into selected hydrocarbons followed by thedistillation of the cleaned, lighter olefin from the hydrocarbons.Alternatively, nickel catalysts can be used to remove the sulfurcontaminants. The equipment required to remove sulfur from an olefin isgenerally quite large in scale and quite expensive to operate.

Additional separations, such as diene removal, iso-alkene removal,and/or paraffin removal may be required depending upon the hydrocarbonsource used in the cracking unit. As an example, the butenes stream froma hydrocarbon cracking unit contains significant amounts of butadieneand isobutene that must be removed. In U.S. Pat. No. 6,049,017 to Voraet al., the butadiene is removed by a controlled hydrogenation process.The isobutene is removed catalytically by contacting the butenes streamwith methanol in a methyl-t-butylether (MTBE) reactor. The isobutene isconverted to MTBE and the normal butenes and butane pass through theMTBE reactor. The normal butenes and butanes are then directed to abutane cracking unit to produce ethylene and propylene or to anoligomerization unit.

Generally, in the production of higher olefin, butanes are not removedfrom the butenes stream because a once through or low recycle higherolefin process is used. Instead, butanes are separated from the higherolefin product, which is a much easier and less costly separation. Forexample, the olefin content of a butenes stream from a steam crackingunit is typically about 60% by weight. The butenes stream is directed tothe higher olefin unit at a conversion per pass of about 50% to 70%.There is little or no recycle, and the butanes are easily separated fromthe higher olefin product. However, there are several disadvantages tothis process. One, 30% to 50% of the olefin in the feed is not convertedto the desired product resulting in overall low process yields. Two, thehigh conversion per pass process results in a lower selectivity to themore desirable alpha-olefins. Alpha-olefins are olefins that contain thecarbon-carbon double bond between the first and second carbon.

A high recycle, low conversion per pass process may address both ofthese disadvantages, however, such a process requires the availabilityof an olefin stream with a high olefin content to maintain the olefinconcentration in the feed at an acceptable level. A butenes stream froma cracking unit, has a low olefin content. Consequently, a significantportion of the paraffins must be removed from the butenes stream if ahigh recycle, low conversion per pass process is to be used. Thisremoval process can be a difficult and expensive task because of therelatively close boiling ranges of the components.

Removing various chemical contaminants from an olefin stream forproducing an olefin derivative product can be a technically difficultprocess depending upon the feed specifications for the process.Therefore, if one could minimize or avoid the paraffin and contaminantremoval process by having available an olefin stream with low levels ofparaffin, alkyl branching, diene, and/or contaminant levels the costs ofremoving these components would be minimized or eliminated altogether.

SUMMARY OF THE INVENTION

The invention provides a method of making a higher olefin product,particularly a mixture of octenes, nonenes, and dodecenes from olefinproduced from an oxygenate to olefin process. The method includescontacting an oxygenate with a molecular sieve catalyst to produce ahydrocarbon product containing olefin, separating a C₄ ⁺ fractioncontaining four or more carbons from the hydrocarbon product, andcontacting the C₄ ⁺ fraction with an oligomerization catalyst to producea product containing higher olefin. Optionally, a portion of theunreacted olefin that was not converted to product can be directed backto the C₄ ⁺ fraction.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention will be better understood by reference to the DetailedDescription of the Invention when taken together with the attacheddrawings, wherein:

FIG. 1 is one embodiment for making a higher olefin;

FIG. 2 is one embodiment for separating the higher olefin product intovarious olefinic components.

DETAILED DESCRIPTION OF THE INVENTION

In order to reduce the associated costs of producing higher olefins,this invention uses a portion of a hydrocarbon product from an oxygenateto olefin unit to make a novel hydrocarbon C₄ ⁺ fraction. Preferably,the oxygenate to olefin unit is a methanol-to-olefin (MTO) unit. This C₄⁺ fraction contains greater than 60% by weight, preferably greater than80% by weight, C₄ ⁺ olefin. The C₄ ⁺ fraction contains a relatively higholefin content, i.e., low amounts of paraffin, very little diene, andrelatively low degree of branched olefin. In the invention an olefinstream with greater than or equal to about 60% by weight olefin isreferred to as an olefin stream having a high olefin content.Conversely, an olefin stream with less than about 60% by weight olefinis referred to an olefin stream having a low olefin content. Also, theC₄ ⁺ fraction contains relatively little or no sulphur and nitrogencompounds that tend to deactivate oligomerization catalysts used in ahigher olefin process.

This invention provides a higher olefin product containing significantamounts of octenes, nonenes, and dodecenes. The higher olefin can thenbe used to make higher alcohols, which may be used as a chemicalfeedstock for a number of commercial plasticizers. The process offersthe advantage in that relatively expensive olefin purification equipmentneed not be used, or if used, smaller purification units are needed whenthe desired C₄ ⁺ fraction is used. In large commercial scale processes,this results in a significant reduction in equipment costs as well as asignificant reduction in operation costs. This reduction in equipmentand operation costs ultimately provides the consumer with a product ofthe same high quality, but at significantly less cost.

In this invention, a hydrocarbon product from an oxygen to olefinreaction unit is directed to separation units, known in the art, toseparate hydrocarbons according to carbon numbers. For example, methaneis separated from the hydrocarbon product followed by, ethylene andethane (C₂ separation), then propylene and propane (C₃ separation). Theremaining portion of the hydrocarbon product, namely the portioncontaining predominantly four and five carbons (C₄ ⁺ fraction), isdirected to a higher olefin unit. Alternatively, the C₄ ⁺ fraction canbe separated in the beginning of the separation sequence to reduce thecapacity requirements of the C₂/C₃ separation unit by as much as 10% to25%.

The C₄ ⁺ fraction contains greater than 60% by weight, preferablygreater than 80% by weight, more preferably greater than 90% by weight,hydrocarbon having four and five carbons. The C₄ ⁺ fraction containsgreater than 60% by weight, preferably greater than 80% by weight,olefin having four carbons (C₄ olefin). Examples of olefin contained inC₄ ⁺ fraction are 1-butene, cis and trans 2-butene, isobutene, and thepentenes. The C₄ ⁺ fraction preferably contains from 60% to 97% byweight, preferably 80% to 97% by weight, olefin. The remainder of the C₄⁺ fraction contains paraffin and small amounts of butadiene and othercomponents. It is desirable that the C₄ ⁺ fraction will more preferablyhave a compositional range as follows: 70% to 95% by weight, morepreferably 80% to 95% by weight, normal butenes, which includes 1-buteneand cis and trans 2-butene; 2 to 8% by weight, preferably less than 6%by weight, isobutene; 0.2% to 5% by weight, preferably less than 3% byweight butanes; 2% to 10% by weight, preferably less than 6% by weight,pentenes; and 2% to 10% by weight, preferably less than 5% by weight,propane and propylene.

It is also desired that the olefin C₄ ⁺ fraction have a low branchingnumber. It is desirable that the average branching number be less than2.0, preferably less than 1.6, more preferably less than 1.4. TheAverage Branching Number (ABN) is defined as:ABN=1+(1*% monobranch+2*% dibranched)/% total olefin

For example, if a dilute olefin stream has 20% 1-butene, 50% 2-butene,10% butane, 10% isobutene, 5% propane, and 5% 3-methylbutene, theaverage branching number is about 1.17. An olefin having near 0%branched olefin will have a ABN of about 1.0.

In one embodiment, the C₄ ⁺ fraction can be used as is, that is,directly from the separation unit to the higher olefin unit.Alternatively, there can be some further processing of the C₄ ⁺ fractionbefore directing it to the higher olefin unit if desired. This mayinclude a hydrogenation process that would selectively hydrogenate mostif not all of the butadiene to butenes and a portion of the isobutene toisobutane. It is also important to limit the amount of isobutene in theolefin feed to minimize the amount of branched higher olefin product.Preferably, the C₄ ⁺ fraction is directed to the higher olefin unitwithout butadiene or isobutene removal.

In another embodiment, purification of the C₄ ⁺ fraction may requireremoval of low level impurities which will interfere with higher olefinreaction unit performance, and/or oxo (hydroformylation) catalystperformance. Low level contaminants will generally comprise polarmolecules. Examples include oxygenates such as water, ethers, alcohols,and carboxylic acids. These compounds can be removed with variousmaterials, such as solid molecular sieves, extraction with varioussolvents, and fractional distillation.

The C₄ ⁺ fraction is typically low in contaminants such as hydrogensulfide, carbonyl sulfide, and arsine. As a result, the C₄ ⁺ fractioncan be directed to a higher olefin unit with minimal separation andpurification. In fact, following separation of the C₄ ⁺ fraction fromthe oxygenate to olefin hydrocarbon product, removal of hydrogensulfide, carbonyl sulfide, or arsine is often not necessary. Desirably,C₄ ⁺ fraction will have a hydrogen sulfide content of less than 20 partsper million by weight (ppmw), preferably less than 5 ppmw., morepreferably less than 1 ppmw. It is also desirable that C₄ ⁺ fractionhave a carbonyl sulfide content of less than 20 ppmw, preferably lessthan 5 ppmw., more preferably less than 1 ppmw. Likewise, it isdesirably that C₄ ⁺ fraction have an arsine content of less than 20ppmw, preferably less than 5 ppmw, more preferably less than 1 ppmw.

Should additional purification of the olefin product stream be needed,purification systems such as that found in Kirk-Othmer Encyclopedia ofChemical Technology, 4th edition, Volume 9, John Wiley & Sons, 1996, pg.894-899, the description of which is incorporated herein by reference,can be used. In addition, purification systems such as that found inKirk-Othmer Encyclopedia of Chemical Technology, 4th edition, Volume 20,John Wiley & Sons, 1996, pg. 249-271, the description of which is alsoincorporated herein by reference, can be also be used.

In another embodiment, the C₄ ⁺ fraction is directed to the higherolefin unit without separating hydrocarbons of different carbon number,olefin from paraffin of like carbon number, or directing the C₄ ⁺fraction to an MTBE unit to remove the isobutene or to a hydrogenationunit to remove butadiene and/or isobutene. As a result, dedicatedfacilities such as distillation units for separating C₄ from C₅hydrocarbons or the butenes from butane, an MTBE unit, and ahydrogenation unit are not required prior to directing the C₄ ⁺ fractionto the higher olefin unit.

In another embodiment, a portion of C₄ ⁺ fraction that is not convertedto product in the higher olefin unit is directed back to the C₄ ⁺fraction. As a result, the hydrocarbon feed to the higher olefin unitwill have a different compositional make-up than the C₄ ⁺ fraction. Thehydrocarbon feed to the higher olefin unit will include hydrocarbonsfrom a recycle stream, which will typically contain relatively moreparaffin than the C₄ ⁺ fraction. The compositional range of thehydrocarbon feed to the higher olefin unit depends upon the desiredspecifications of the higher olefin product, the oligomerizationcatalyst, the reaction conditions in the oligomerization unit, theamount of recycled hydrocarbon, and the composition of the C₄ ⁺fraction.

The low paraffin and contaminant content of C₄ ⁺ fraction provides theoperational flexibility of running a high recycle, low conversion perpass higher olefin process. The invention allows unreacted olefin fromthe higher olefin unit to be recycled without significantly adding tothe overall load of the higher olefin unit and recovery facilities andwithout significant risk of accumulating contaminants that maydeactivate the olgomerization catalyst. By using a feed that is low inparaffin and low in harmful contaminants with a higher olefin unit thatutilizes a high recycle, low conversion per pass process, the overallyield and isomer selectivity of the higher olefin product can besignificantly increased. A high recycle, low conversion per pass higherolefin process can convert greater than 80%, often greater than 90%, ofthe olefin in the process. Also, the high recycle provides greateroperational flexibility to optimize the product selectivity toalpha-olefins, such as 1-octene.

In contrast, a conventional once through, high conversion higher olefinprocess will typically convert less than 80%, often less than 70%, ofthe olefin in the process. Also, because the conventional higher olefinunit operates at a relatively high conversion per pass, the selectivityto a more desirable higher olefin product is lower. Desired higherolefin product will contain relatively higher amounts of alpha-olefinand have a relatively low branching number.

A high recycle, low conversion per pass higher olefin process requiresthe availability of an olefin feed with a high olefin content to keepthe purge volume to a minimum. In one embodiment, a C₄ ⁺ fraction with abutenes concentration between 70 and 97% by weight is directed to ahigher olefin unit. The C₄ ⁺ fraction is mixed with the hydrocarbonsfrom the recycle stream to produce an optimal hydrocarbon feedcomposition to the higher olefin unit. The optimal hydrocarbon feedcomposition will vary depending upon the recycle and olefin conversionpercentages in the higher olefin unit. The hydrocarbon feed compositionmay vary between 20 to 95% by weight butenes. The paraffins are used asa diluent to control the rate of reaction in the higher olefin process.The low amount of paraffins in the C₄ ⁺ fraction also minimizes thevolume of purge gas needed to control the level of inerts in thehydrocarbon feed. This minimizes the amount of olefin lost in the purgestream.

The high recycle process will have an olefin conversion per pass ratioof between 30% and 70%, preferably between 40% and 70%, more preferablybetween 45% and 70%. The total olefin conversion can be as high as 80%to 98%, preferably from 90% to 98%. Another advantage of using a highrecycle, low conversion per pass process is that the productselectivity, e.g., the isomer selectivity to 1-octene, can be optimized.

One embodiment of a high recycle process is shown in FIG. 1. C ₄ ⁺fraction 12 produced in an oxygenate to olefin unit 10 is directed to ahigher olefin unit 14. The product 16 containing higher olefin andunreacted olefin and paraffins is directed to a product separation unit15. The higher olefin product 17, namely the octenes, nonenes anddodecenes, are separated from the unreacted olefin and paraffin, andthen directed to additional separation units. These separation units arerepresented as 15 b, 15 c, 15 d, and 15 e in FIG. 2. The vent stream 18contains unreacted olefin and inerts, including paraffins. The ventstream 18 comprises 40% to 90% by weight olefin. A portion of the ventstream 18 is removed via purge stream 22 to maintain the inerts balancein the higher olefin unit to a specific compositional range, which inturn maintains the olefins at the desired concentration in thehydrocarbon feed to the higher olefin unit 14. The remainder of the ventstream 18 is recycled to the olefin reaction unit 14 via recycle stream26.

Another embodiment includes removing at least a portion of the paraffinand undesirable olefin from the vent stream 18 using one or moreseparation units. Examples of olefin separation units include fractionaldistillation equipment, including dephlegmators, and absorption,extractive or membrane separation equipment, and combinations thereof.Preferably, the olefin separation units are one or more fractionaldistillation units. Preferably, the fractional distillation unit isoperated without the use of a lean physical solvent. Example compoundsremoved from the vent stream 18 include butane and isobutane. After adesired portion of such compounds have been removed as a purge stream,the desired separated olefins can be recycled to the higher olefin unit14 via recycle stream 26.

Once the total amount of paraffins and olefin to the higher olefin unit14 is set, the mass flow of vent stream 18 is determined by the desiredextent of removal of the paraffin and olefin through olefin purge stream22, and the recycle ratio in the process. In a preferred embodiment, atleast 50% by weight of the paraffins in vent stream 18 are removedthrough purge stream 22, more preferably at least 75% by weight, andmost preferably at least 90% by weight. A greater percentage ofparaffins will be removed if a separation unit is positioned in the ventstream 18. Preferably, purge stream 22 will comprise no more than 50% byweight, more preferably no more than 20% by weight, and most preferablyno more than 5% by weight, olefin.

Preferably the olefin recycle stream 26 comprises at least 50% by weightof the olefin contained in the vent stream 18, more preferably at least75% by weight, and most preferably at least 90% by weight. The balanceof the recovered olefin stream 26 may comprise paraffins and othermaterials found in the vent stream 18.

Most if not all known processes known in the art can be used tooligomerize

C₄ ⁺ fraction to higher olefins having eight or more carbons. Solidphosphoric acid polymerization is the commonly used process for theoligomerization of butenes. In the process the butenes are fed to amultibed reactor containing solid phosphoric acid, which is made from apelletized and calcined mixture of phosphoric acid on kieselguhr.Operating conditions are 175° C. to 225° C. and pressures of at least 20atm. The higher olefin selectivity is relatively poor, and for thisreason the process is often associated with petroleum refining to ensureeconomical use of the less value products. Also, the disposal of thecatalyst in landfills presents environmental issues and related costs.

Dimersol® is a commercial process that produces a more linear olefinthan the phosphoric acid process. The reaction is carried out at 50° C.to 80° C. and about 1600 kPa to 1800 kPa in the liquid phase using ahomogeneous nickel-alkyl aluminum catalyst. Ammonia and water areinjected into the product stream to neutralize the catalyst, and thehydrocarbon is then separated from the aqueous phase. The catalyst isthen recovered and recycled back to the reactor.

In another embodiment, a modified ZSM-22 catalyst can be used as anoligomerization catalyst. U.S. Pat. No. 6,013,851 to Verrelst et al.,the disclosure of which is incorporated herein by reference, describes amodified ZSM-22 olefin oligomerization molecular sieve catalyst whereinthe molecular sieve contains a metal-silicon core and surface layer,with the surface layer having a higher silicon metal ratio than that ofthe core. The metal is selected from aluminum, gallium and iron. Thiscatalyst reduces the amount of branched higher olefin produced in theprocess. Also, the presence of some paraffin in the olefin feed has noor little effect on the catalytic efficiency of the catalyst. As aresult, the relatively small amounts of butane in C₄ ⁺ fraction does nothave to be separated from the feed. For example, a 1:1, preferably 2:1,ratio of butene:butane can be used. Small amounts of water are alsoshown to enhance the production of desired higher olefin.

Using the modified ZSM-22 catalyst in a high recycle, higer olefinprocess the product selectivity to octene is retained with a decrease inthe amount of branching. For example, using C₄ ⁺ fraction as feed,octene selectivity can exceed 80%. An octene selectivity greater than90% can be achieved with a higher recycle ratio. The oligomerization maytake place at a temperature in the range of from 160° C. to 300° C.,preferably from 170° C. to 260° C., and most preferably from 180° C. to260° C., at a pressure advantageously in the range of from 5 MPa to 10MPa, preferably from 6 MPa to 8 MPa, and at an olefin hourly spacevelocity advantageously in the range 0.1 hr⁻¹ to 20 hr⁻¹, preferablyfrom 0.5 hr⁻¹ to 10 hr⁻¹, and most preferably 0.75 hr⁻¹ to 3.5 hr⁻¹.

In another embodiment, the oligomerization of C₄ ⁺ fraction olefin canbe carried out in the presence of a nickel oxide (NiO) catalyst asdescribed in U.S. Pat. No. 5,254,783 to Saleh et al., the disclosure ofwhich is incorporated herein by reference. The catalyst containsamorphous NiO present as a disperse monolayer on the surfaces of asilica support. The support also contains minor amounts of an oxide ofaluminum, gallium or indium such that the ratio of NiO to metal oxidepresent in the catalyst is within the range of from about 4:1 to about100:1. The catalyst converts linear butenes to octene products having onaverage less than about 2.6, generally less than 2.0 to 2.4. methylgroups per molecule.

The NiO catalyst is particularly effective for the dimerization ofbutene to form a mixed polymerization product composed mainly ofoctenes. Preferably, the C₄ ⁺ OTO will not contain more than 5% byweight of isobutene, because isobutene tends to form products with ahigh degree of branching. The desired isobutene concentrations can beachieved by selectivity hydrogenating C₄ ⁺ OTO. The presence ofparaffins in the olefin feed is not generally detrimental, but if theproportion rises above 80% by weight the process becomes uneconomical.

The oligomerization using a NiO catalyst is carried out in either theliquid or gas phase. Temperature conditions include a temperature from150° C. to 275° C. and, in the gas phase, a liquid hourly weight feedrate of butene over the catalyst of from 0.4 hr⁻¹ to 1.8 hr⁻¹,preferably from 0.6 hr⁻¹ to 0.7 hr⁻¹. Where the oligomerization reactionis conducted in the liquid phase and the catalyst is mixed with theolefin, it is preferred that the ratio of olefin to catalyst be in therange of from 2:1 to 8:1, more preferably from 4:1 to 6:1. In caseswhere the oligomerization is conducted under pressure near, at or abovethe critical temperature of the olefin, it is often desirable to insurethat the liquid phase is maintained by carrying out the reaction in thepresence of an inert higher boiling hydrocarbon such as a normalparaffin or cycloparaffin.

In another embodiment, a ZSM-57 catalyst can be used as anoligomerization catalyst. ZSM-57 provides high product selectivity tooctenes with a decrease in the amount of branching product and crackingof the olefin. Also, the ZSM-57 catalyst exhibits a relatively higherreactivity with pentenes that are also present in C₄ ⁺ OTO. As a result,the yield of nonenes is increased in the process. In fact, additionalpentenes can be added to C₄ ⁺ OTO from an external source to boost theyields of nonene in the process. The oligomerization may take place at atemperature in the range of from 80° C. to 400° C., preferably from 120°C. to 300° C., and most preferably from 150° C. to 280° C., at apressure advantageously in the range of from 2 MPa to 15 MPa, preferablyfrom 5 MPa to 10 MPa, and at an olefin hourly space velocityadvantageously in the range 0.1 hr⁻¹ to 30 hr⁻¹, preferably from 0.5hr⁻¹ to 15 hr⁻¹, and most preferably 0.75 hr⁻¹ to 8 hr⁻¹.

FIG. 2 depicts separation unit 15 divided into several separation units15 a, 15 b, 15 c, 15 d, and 15 e. In one embodiment, separation units 15a-15 e can be designed as follows. Separation unit 15 b removes thepentenes and hexenes 17 b from the higher olefin product 16. Thepentenes and hexenes 17 b can be used as fuel and/or may also bedirected to the higher olefin reaction unit 14. The recycled pentenesand hexenes 17 b can combine with C₄ ⁺ fraction 12 to form additionalnonene and decane, respectively. Separation unit 15 c removes theheptenes 17 c, separation unit 15 d removes the octenes 17 d, andseparation unit 15 e removes the nonene 17 e. Other separation units canbe used to separate the remainder of the higher olefin product. Forexample, it may be desirable to separate the significant amount ofdodecenes from the C₁₀-C₂₀ higher olefin 19 to produce C₁₃-alcohols. TheC₁₀-C₂₀ higher olefin 19 can also be used as chemical feedstock forother commercial value products, such as jet fuel or high qualitysolvents. The separations according to carbon number may be carried outusing methods known in the art as described in Kirk-Othmer, Encyclopediaof Chemical Technology, 4th edition, Volume 20, John Wiley & Sons, 1996,the disclosure of which is incorporated herein by reference.

Because C₄ ⁺ OTO contains mostly butenes, the product expected from ahigher olefin unit will contain primarily octenes (about 70%), dodecenes(about 17%) as well as some nonenes (about 5%) and C₁₆-C₂₀ alkenes(about 5%). These percentages will vary depending upon the type ofoligomerization catalyst used and the hydrocarbon feed composition.

It may, be desirable to produce additional nonene from the higher olefinunit. One way of accomplishing this task is to feed additional C₅ olefinto the higher olefin unit. The source of the C₅ olefin may come from asteam cracker, or from the small amount produced by the higher olefinunit. Additional C₅ olefin may also be obtained from catalyticallycracking the higher olefin product such as the heptane and C₁₀ to C₂₀olefin.

Following separation of the higher olefin product into the desiredhigher olefin components based on carbon numbers, the respectiveseparated higher olefin can be directed to one or more hydroformylationunits. In one embodiment, the octenes and nonenes can be directed tohydroformylation units to produce nonanyl alcohol and decyl alcohol,respectively. The remaining portion of the higher olefin product, thatis, higher olefin with ten or more carbons can be directed to ahydrogenation unit. The hydrogenated products can be used as blendingcomponents to increase the quality of diesel or aviation fuel. A portionof the octene and nonene not directed to the hydroformylation units mayalso be directed to the hydrogenation unit.

One hydroformulation process that may be used is commonly referred to asthe oxo-process. In the oxo-process, an olefin reacts with carbonmonoxide and hydrogen at elevated temperature and pressure in thepresence of a catalyst to produce predominately two isomeric aldehydes:a terminal or normal, aldehyde, and an internal, or branched, aldehyde.The position of the formyl group in the aldehyde product depends uponthe olefin, the catalyst, the solvent, and the reaction conditions.Typically, the use of catalysts with strictly encompassing complexingligands, e.g., tertiary phosphines, results predominately in theformation of the normal aldehyde. In most commercial processes theinitially formed aldehyde product is not isolated. Rather, the aldehydesare further converted to alcohols by a hydrogenation process or by analdolization/hydrogeneration process. Purification of higher molecularweight alcohols usually includes low pressure distillation orseparations involving falling film evaporators.

A variety of transition metals catalyze the conversion of olefin toaldehydes, but typically only cobalt and rhodium complexes are used incommercial oxo plants. A commercial oxo process involving a conventionalcobalt catalyst may include at least the following steps:hydroformylation, that is, the formation of the aldehyde, removal andrecovery of catalyst, aldehyde refining, hydrogenation, and finallyalcohol refining. In addition, commercial plants may use thealdolization/hydrogenation process to convert the aldehydes to alcohols.Commercial hydroformylations are carried out continuously in either backmixed or tubular stainless steel reactors or in combinations of the two.In the back mixed reactor, the composition of the reaction mixture isconstant and close to that of product. In the tubular reactor, thecomposition changes continually with time because of plug flow throughlong narrow tubes. Reaction conditions vary depending on the olefinfeed, but generally are 100° C. to 180° C. and 20 MPa to 35 MPa. Thepressure used is determined by the catalyst stability at a particularreaction temperature. Catalyst concentrations of about 0.1% to 1% cobaltbased on olefin and liquid residence times of 1 hour to 2 hours arecommon.

Conversion of crude oxo aldehydes to alcohols is accomplished byheterogenous vapor or liquid phase hydrogenation in fixed bed reactors.Among the metals that have been used as catalysts for thesehydrogenations are copper, nickel, tungsten, cobalt, molybdenum sulfide,and various combination of these metals. Because sulfur poisoning is nota concern in this invention, nickel or cobalt containing catalysts arepreferred. Catalysts frequently are placed on inert supports by reactionof the corresponding metal oxides with hydrogen.

The hydrogenation of oxo-products are typically carried out at 100° C.to 250° C.; the specific conditions are dictated by the catalyst beingused and the desired conversion. The vapor phase process is operated atlow pressures, and the liquid phase process is operated up to pressuresof 35 MPa. Internal or external cooling, or both, are required to removeheat from the reaction.

The use of a cobalt carbonyl catalyst modified by organic phosphineligands can significantly improve hydroformylation selectivity to themore desirable terminal aldehydes, which in turn will most likely leadto terminal alcohols. Although these phosphine modified, cobaltcatalysts are less reactive than uncomplexed cobalt carbonyls, they canbe used at higher reaction temperatures, i.e., 150° C. to 210° C., andlower pressures 2 MPa to 10 MPa. These catalysts are also activehydrogeneration catalysts. As a result, the hydroformylation and much ofthe hydrogenation steps occurs in the same reactor, thus producingpredominately alcohols if the H₂ to CO ratio in the feed synthesis isabout 2 to 1. This single step process, along with a strong preferenceof the catalysts for the reaction at the terminal position of linearolefins makes it possible to prepare alcohols with a high linear tobranched ratio from mixtures of internal and terminal linear olefins.

The formation of linear aldehydes is also favored by ligand modifiedrhodium carbonyl catalysts. Typical complex catalyst concentrationscontain from 50 ppm to 150 ppm of rhodium. Additional information oncommercial oxo-processes is described in Kirk-Othmer, Encyclopedia ofChemical Technology, 3rd edition, Vol. 16, John Wiley & Sons, pp.637-653.

The C₄ ⁺ OTO according to this invention is produced in an oxygenate toolefin process. The oxygenate to olefin process uses small pore, zeoliteor non-zeolite molecular sieve catalyst to catalyze conversion of anoxygenate, such as methanol, to primarily C₂ to C₄ ⁺ olefin. Zeolitemolecular sieve are complex crystalline aluminosilicates which form anetwork of AlO₂ ⁻ and SiO₂ tetrahedra linked by shared oxygen atoms. Thenegativity of the tetrahedra is balanced by the inclusion of cationssuch as alkali or alkaline earth metal ions. In the manufacture of somezeolites, non-metallic cations, such as tetramethylammonium (TMA) ortetrapropylammonium (TPA), are present during synthesis.

Zeolites include materials containing silica and optionally alumina, andmaterials in which the silica and alumina portions have been replaced inwhole or in part with other oxides. For example, germanium oxide, tinoxide, and mixtures thereof can replace the silica portion. Boron oxide,iron oxide, gallium oxide, indium oxide, and mixtures thereof canreplace the alumina portion. Unless otherwise specified, the terms“zeolite” and “zeolite material” as used herein, shall mean not onlymaterials containing silicon atoms and, optionally, aluminum atoms inthe crystalline lattice structure thereof, but also materials whichcontain suitable replacement atoms for such silicon and aluminum atoms.

Non-zeolite, silicoaluminophosphate molecular sieves are preferred foruse in connection with this invention. These sieves generally comprise athree-dimensional microporous crystal framework structure of [SiO₂],[AlO₂] and [PO₂] tetrahedral units. In general, silicoaluminophosphatemolecular sieves comprise a molecular framework of corner-sharing[SiO₂], [AlO₂], and [PO₂] tetrahedral units. This type of framework iseffective in converting various oxygenates into olefin products.

It is preferred that the silicoaluminophosphate molecular sieve used inthis invention have a relatively low Si/Al₂ ratio. In general, the lowerthe Si/Al₂ ratio, the lower the C₁-C₄ saturates selectivity,particularly propane selectivity. A Si/Al₂ ratio of less than 0.65 isdesirable, with a Si/Al₂ ratio of not greater than 0.40 being preferred,and a Si/Al₂ ratio of not greater than 0.32 being particularlypreferred. A Si/Al₂ ratio of not greater than 0.20 is most preferred.

Silicoaluminophosphate molecular sieves are generally classified asbeing microporous materials having 8, 10, or 12 membered ringstructures. These ring structures can have an average pore size rangingfrom about 3.5-15 angstroms. Preferred are the small pore SAPO molecularsieves having an average pore size of less than about 5 angstroms,preferably an average pore size ranging from about 3.5 to 5 angstroms,more preferably from 3.5 to 4.2 angstroms. These pore sizes are typicalof molecular sieves having 8 membered rings.

Substituted SAPOs can also be used in this invention. These compoundsare generally known as MeAPSOs or metal-containingsilicoaluminophosphates. The metal can be alkali metals (Group IA),alkaline earth metals (Group IIA), rare earth metals (Group IIIB,including the lanthanide elements), and the transition metals of GroupsIB, IIB, IVB, VB, VIIB, VIIB, and VIIIB. Incorporation of the metalcomponent is typically accomplished adding the metal component duringsynthesis of the molecular sieve. However, post-synthesis ion exchangecan also be used as disclosed in U.S. Pat. No. 5,962,762 to Sun et al.and U.S. patent application Ser. No. 09/615,526, the disclosures ofwhich are incorporated herein by reference.

Suitable silicoaluminophosphate molecular sieves include SAPO-5, SAPO-8,SAPO-11, SAPO-16, SAPO-17, SAPO-18, SAPO-20, SAPO-31, SAPO-34, SAPO-35,SAPO-36, SAPO-37, SAPO-40, SAPO-41, SAPO-42, SAPO-44, SAPO-47, SAPO-56,the metal containing forms thereof, and mixtures thereof. Preferred areSAPO-17, SAPO-18, SAPO-34, SAPO-35, SAPO-44, and SAPO-47, particularlySAPO-17, SAPO-18 and SAPO-34, including the metal containing formsthereof, and mixtures thereof. As used herein, the term mixture issynonymous with combination and is considered a composition of matterhaving two or more components in varying proportions, regardless oftheir physical state.

The silicoaluminophosphate molecular sieves are synthesized byhydrothermal crystallization methods generally known in the art. See,for example, U.S. Pat. Nos. 4,440,871; 4,861,743; 5,096,684; and5,126,308, the methods of making of which are fully incorporated hereinby reference. A reaction mixture is formed by mixing together reactivesilicon, aluminum and phosphorus components, along with at least onetemplate. Generally the mixture is sealed and heated, preferably underautogenous pressure, to a temperature of at least 100° C., preferablyfrom 100-250° C., until a crystalline product is formed. Formation ofthe crystalline product can take anywhere from around 2 hours to as muchas 2 weeks. In some cases, stirring or seeding with crystalline materialwill facilitate the formation of the product.

The SAPO molecular sieve structure can be effectively controlled usingcombinations of templates. For example, in a particularly preferredembodiment, the SAPO molecular sieve is manufactured using a templatecombination of TEAOH and dipropylamine. This combination results in aparticularly desirable SAPO structure for the conversion of oxygenates,particularly methanol and dimethyl ether, to light olefins such asethylene and propylene.

The silicoaluminophosphate molecular sieve is typically admixed (i.e.,blended) with other materials. When blended, the resulting compositionis typically referred to as a SAPO catalyst, with the catalystcomprising the SAPO molecular sieve.

Materials which can be blended with the molecular sieve can be variousinert or catalytically active materials, or various binder materials.These materials include compositions such as kaolin and other clays,various forms of rare earth metals, metal oxides, other non-zeolitecatalyst components, zeolite catalyst components, alumina or aluminasol, titania, zirconia, magnesia, thoria, beryllia, quartz, silica orsilica or silica sol, and mixtures thereof. These components are alsoeffective in reducing, inter alia, overall catalyst cost, acting as athermal sink to assist in heat shielding the catalyst duringregeneration, densifying the catalyst and increasing catalyst strength.It is particularly desirable that the inert materials that are used inthe catalyst to act as a thermal sink have a heat capacity of from about0.05 cal/g-° C. to about 1 cal/g-° C., more preferably from about 0.1 toabout 0.8 cal/g-° C., most preferably from about 0.1 cal/g-° C. to about0.5 cal/g-° C.

The catalyst composition preferably comprises about 1% to about 99%,more preferably about 5% to about 90%, and most preferably about 10% toabout 80%, by weight of molecular sieve. It is also preferred that thecatalyst composition have a particle size of from about 20μ to 3,000μ,more preferably about 30μ to 200μ, most preferably about 50μ to 150μ.

Any standard reactor system can be used in the oxygenate to olefinprocess including fixed bed, fluid bed or moving bed systems. Preferredreactors are co-current riser reactors and short contact time,countercurrent free-fall reactors. Desirably, the reactor is one inwhich an oxygenate feedstock can be contacted with a molecular sievecatalyst at a weight hourly space velocity (WHSV) of at least about 1hr⁻¹, preferably in the range of from about 1 hr⁻¹ to about 1000 hr⁻¹,more preferably in the range of from about 20 hr⁻¹ to about 1000 hr⁻¹,and most preferably in the range of from about 20 hr⁻¹ to about 500hr⁻¹. WHSV is defined herein as the weight of oxygenate, and hydrocarbonwhich may optionally be in the feed, per hour per weight of themolecular sieve content of the catalyst. Because the catalyst or thefeedstock may contain other materials which act as inerts or diluents,the WHSV is calculated on the weight basis of the oxygenate feed, andany hydrocarbon which may be present, and the molecular sieve containedin the catalyst.

Preferably, the oxygenate feed is contacted with the catalyst when theoxygenate is in a vapor phase. Alternately, the process may be carriedout in a liquid or a mixed vapor/liquid phase. When the process iscarried out in a liquid phase or a mixed vapor/liquid phase, differentconversions and selectivities of feed-to-product may result dependingupon the catalyst and reaction conditions.

The process can generally be carried out at a wide range oftemperatures. An effective operating temperature range can be from about200° C. to about 700° C., preferably from about 300° C. to about 600°C., more preferably from about 350° C. to about 550° C. At the lower endof the temperature range, the formation of the desired olefin productsmay become markedly slow. At the upper end of the temperature range, theprocess may not form an optimum amount of product.

The pressure also may vary over a wide range, including autogenouspressures. Effective pressures may be in, but are not necessarilylimited to, oxygenate partial pressures at least 1 psia, preferably atleast 5 psia. The process is particularly effective at higher oxygenatepartial pressures, such as an oxygenate partial pressure of greater than20 psia. Preferably, the oxygenate partial pressure is at least about 25psia, more preferably at least about 30 psia. For practical designpurposes it is desirable to operate at a methanol partial pressure ofnot greater than about 500 psia, preferably not greater than about 400psia, most preferably not greater than about 300 psia.

The conversion of oxygenates to produce light olefins may be carried outin a variety of catalytic reactors. Reactor types include conventionalreactors such as fixed bed reactors, fluid bed reactors, and riserreactors. Preferred reactors are riser reactors.

Having now fully described this invention, it will be appreciated bythose skilled in the art that the invention can be performed within awide range of parameters within what is claimed, without departing fromthe spirit and scope of the invention.

1. A method of making olefin derivatives from an oxygenate comprising:contacting the oxygenate with a molecular sieve catalyst to produce ahydrocarbon product containing olefin; separating a C4+ fractioncontaining four or more carbons from the hydrocarbon product wherein theC4+ fraction comprises from about 80% to about 97% by weight butenes andfrom about 3% to about 20% by weight butanes; contacting the C4+fraction with an oligomerization catalyst to produce a productcontaining higher olefin and a vent stream; separating the vent streamfrom the higher olefin; and contacting a portion of the separated ventstream with the oligomerzation catalyst.
 2. The method of claim 1wherein the butenes comprise from about 20% to about 40% by weight1-butene, and from about 60% to about 80% by weight 2-butene.
 3. Themethod of claim 1 wherein the olefin product comprises less than 20 ppmwby weight of an individual contaminant, the individual contaminentsselected from the group consisting of hydrogen sulfide, carbonylsulfide, and arsine.
 4. The method of claim 1 wherein the molecularsieve catalyst is selected from the group consisting of SAPO-17,SAPO-18, SAPO-34, SAPO-35, SAPO-44, SAPO-56, ZSM-5, ZSM-22, ZSM-35, themetal containing forms of each thereof, and mixtures thereof.
 5. Themethod of claim 1 wherein the oligomerization catalyst is selected fromthe group consisting of nickel-alkyl aluminum, solid phosphoric acid,nickel-oxide, and ZSM-57.
 6. The method of claim 1 further comprisingcontacting a portion of the product containing higher olefin with ahydroformylation catalyst.
 7. The method of claim 1 further comprisingseparating octenes from the product containing higher olefin andcontacting a portion of the octenes with a hydroformylation catalyst toform nonanyl alcohols.
 8. The method of claim 1 further comprisingseparating nonenes from the product containing higher olefin andcontacting a portion of the nonenes with a hydroformylation catalyst toform decyl alcohols.
 9. The method of claim 1 further comprisingseparating dodecenes from the product containing higher olefin andcontacting a portion of the dodecenes with a hydrogenation catalyst toform dodecanes.